Jaw assemblies for electrosurgical instruments and methods of manufacturing jaw assemblies

ABSTRACT

A jaw assembly includes an electrically-conductive tissue-engaging structure, a jaw member including a support base, and a non-electrically conductive member including a first portion configured to engage the electrically-conductive tissue-engaging structure and a second portion configured to engage the support base of the jaw member. The non-electrically conductive member adapted to electrically isolate the electrically-conductive tissue-engaging structure from the jaw member. The electrically-conductive tissue-engaging structure and the non-electrically conductive member cooperatively define a longitudinally-oriented knife channel therethrough.

CROSS REFERENCE TO RELATED APPLICATION

The present application claims the benefit of and priority to U.S.Provisional Application Ser. No. 61/711,075, filed on Oct. 8, 2012, theentire contents of which are incorporated herein by reference.

BACKGROUND

1. Technical Field

The present disclosure relates to electrosurgical instruments. Moreparticularly, the present disclosure relates to jaw assemblies for usein electrosurgical instruments and methods of manufacturing jawassemblies.

2. Discussion of Related Art

Electrosurgical instruments have become widely used by surgeons.Electrosurgery involves the application of thermal and/or electricalenergy to cut, dissect, ablate, coagulate, cauterize, seal or otherwisetreat biological tissue during a surgical procedure. Electrosurgery istypically performed using an electrosurgical generator operable tooutput energy and a handpiece including a surgical instrument (e.g., endeffector) adapted to transmit energy to a tissue site duringelectrosurgical procedures. Electrosurgery can be performed using eithera monopolar or a bipolar instrument.

The basic purpose of both monopolar and bipolar electrosurgery is toproduce heat to achieve the desired tissue/clinical effect. In monopolarelectrosurgery, devices use an instrument with a single, activeelectrode to deliver energy from an electrosurgical generator to tissue,and a patient return electrode or pad that is attached externally to thepatient (e.g., a plate positioned on the patient's thigh or back) as themeans to complete the electrical circuit between the electrosurgicalgenerator and the patient. When the electrosurgical energy is applied,the energy travels from the active electrode, to the surgical site,through the patient and to the return electrode. In bipolarelectrosurgery, both the active electrode and return electrode functionsare performed at the site of surgery. Bipolar electrosurgical devicesinclude two electrodes that are located in proximity to one another forthe application of current between their surfaces. Bipolarelectrosurgical current travels from one electrode, through theintervening tissue to the other electrode to complete the electricalcircuit. Bipolar instruments generally include end-effectors, such asgrippers, cutters, forceps, dissectors and the like.

Forceps utilize mechanical action to constrict, grasp, dissect and/orclamp tissue. By utilizing an electrosurgical forceps, a surgeon canutilize both mechanical clamping action and electrosurgical energy toeffect hemostasis by heating the tissue and blood vessels to cauterize,coagulate/desiccate, seal and/or divide tissue. Bipolar electrosurgicalforceps utilize two generally opposing electrodes that are operablyassociated with the inner opposing surfaces of end effectors and thatare both electrically coupled to an electrosurgical generator. Inbipolar forceps, the end-effector assembly generally includes opposingjaw assemblies pivotably mounted with respect to one another. In bipolarconfiguration, only the tissue grasped between the jaw assemblies isincluded in the electrical circuit. Because the return function isperformed by one jaw assembly of the forceps, no patient returnelectrode is needed.

By utilizing an electrosurgical forceps, a surgeon can cauterize,coagulate/desiccate and/or seal tissue and/or simply reduce or slowbleeding by controlling the intensity, frequency and duration of theelectrosurgical energy applied through the jaw assemblies to the tissue.During the sealing process, mechanical factors such as the pressureapplied between opposing jaw assemblies and the gap distance between theelectrically-conductive tissue-contacting surfaces (electrodes) of thejaw assemblies play a role in determining the resulting thickness of thesealed tissue and effectiveness of the seal.

A variety of types of end-effector assemblies have been employed forvarious types of electrosurgery using a variety of types of monopolarand bipolar electrosurgical instruments. Jaw assembly components ofend-effector assemblies for use in electrosurgical instruments arerequired to meet specific tolerance requirements for proper jawalignment and other closely-toleranced features, and are generallymanufactured by expensive and time-consuming processes that typicallyinvolve complex machining operations. Gap tolerances and/or surfaceparallelism and flatness tolerances are parameters that, if properlycontrolled, can contribute to a consistent and effective tissue seal.Thermal resistance, strength and rigidity of surgical jaw assembliesalso play a role in determining the reliability and effectiveness ofelectrosurgical instruments.

SUMMARY

A continuing need exists for tightly-toleranced jaw assembly componentsthat can be readily integrated into manufacturing assembly processes forthe production of end-effector assemblies for use in electrosurgicalinstruments, such as electrosurgical forceps. Further need exists forthe development of a manufacturing process that effectively fabricatesjaw assembly components at low cost, and results in the formation of areliable electrosurgical instrument that meets specific tolerancerequirements for proper jaw alignment and other tightly-toleranced jawassembly features, with reduction or elimination of complex machiningoperations.

A continuing need exists for a reliable electrosurgical instrument thatregulates the gap distance between opposing jaw assemblies, reduces thechances of short circuiting the opposing jaws during activation, andassists in gripping, manipulating and holding tissue prior to and duringactivation and dividing of the tissue. A continuing need exists forimproved thermal resistance, strength and rigidity of jaw assembliesusing lower cost technologies.

According to an aspect, a jaw assembly is provided. The jaw assemblyincludes an electrically-conductive tissue-engaging structure, a jawmember including a support base, and a non-electrically conductivemember including a first portion configured to engage theelectrically-conductive tissue-engaging structure and a second portionconfigured to engage the support base of the jaw member. Thenon-electrically conductive member adapted to electrically isolate theelectrically-conductive tissue-engaging structure from the jaw member.The electrically-conductive tissue-engaging structure and thenon-electrically conductive member cooperatively define alongitudinally-oriented knife channel therethrough.

According to an aspect, an end-effector assembly is provided. Theend-effector assembly includes opposing first and second jaw assembliespivotably mounted with respect to one another. The first jaw assemblyincludes a first jaw member including a first arm member defining one ormore apertures at least partially therethrough and a first support baseextending distally from the first arm member. The second jaw assemblyincludes a second jaw member including a second arm member defining oneor more apertures at least partially therethrough and a second supportbase extending distally from the second arm member. The first jawassembly further includes a first electrically-conductivetissue-engaging structure and a first non-electrically conductivemember. The first non-electrically conductive member includes a firstportion configured to engage the first electrically-conductivetissue-engaging structure and a second portion configured to engage thefirst support base of the first jaw member. The second jaw assemblyfurther includes a second electrically-conductive tissue-engagingstructure and a second non-electrically conductive member. The secondnon-electrically conductive member includes a first portion configuredto engage the second electrically-conductive tissue-engaging structureand a second portion configured to engage the second support base of thesecond jaw member. One or more pivot pins are engaged with the one ormore apertures of the first and second jaw members such that the firstand second jaw assemblies are pivotably mounted with respect to oneanother.

The first jaw assembly and/or the second jaw assembly may be adapted toconnect the electrically-conductive tissue-engaging structure associatedtherewith to an electrosurgical generator

According to another aspect, a method of manufacturing a jaw assembly isprovided. The method includes the initial steps of providing anelectrically-conductive tissue-engaging structure, providing a jawmember including a support base, and providing a non-electricallyconductive member including a first portion configured to engage theelectrically-conductive tissue-engaging structure and a second portionconfigured to engage the support base of the jaw member. Thenon-electrically conductive member is adapted to electrically isolatethe electrically-conductive tissue-engaging structure from the jawmember. The method also includes the steps of providing a fixtureassembly configured to hold the electrically-conductive tissue-engagingstructure in position with respect to the first portion of thenon-electrically conductive member and to hold the support base inposition with respect to the second portion of the non-electricallyconductive member, and performing a brazing process to join theelectrically-conductive tissue-engaging structure, non-electricallyconductive member and the jaw member using the fixture assembly, therebyforming a jaw assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

Objects and features of the presently-disclosed jaw assemblies for usein electrosurgical instruments and methods of manufacturing jawassemblies will become apparent to those of ordinary skill in the artwhen descriptions of various embodiments thereof are read with referenceto the accompanying drawings, of which:

FIG. 1 is a right, side view of an endoscopic bipolar forceps showing ahousing, a rotatable member, a shaft and an end-effector assembly inaccordance with an embodiment of the present disclosure;

FIG. 2 is a perspective view of an open bipolar forceps according to anembodiment of the present disclosure;

FIG. 3A is a schematic diagram of a jaw assembly including an electrodetip portion in accordance with an embodiment of the present disclosure;

FIG. 3B is a side view of the jaw assembly shown in FIG. 3A;

FIG. 4 is a schematic diagram of a jaw assembly in accordance with anembodiment of the present disclosure;

FIG. 5 is an enlarged, cross-sectional view taken along the sectionlines 5-5 of FIG. 4;

FIG. 6 is an enlarged, cross-sectional view of the jaw assembly of FIG.5 shown disposed within a fixture assembly, such as during an assemblyprocess, in accordance with an embodiment of the present disclosure;

FIG. 7 is an enlarged, perspective view of an embodiment of an upper jawassembly of an end-effector assembly, such as the end-effector assemblyof the forceps shown in FIG. 1, with parts separated in accordance withthe present disclosure;

FIG. 8 is an enlarged, perspective view of an embodiment of a lower jawassembly of an end-effector assembly, such as the end-effector assemblyof the forceps shown in FIG. 1, with parts separated in accordance withthe present disclosure;

FIG. 9 is a flowchart illustrating a method of manufacturing a jawassembly in accordance with an embodiment of the present disclosure;

FIG. 10A is a schematic diagram of a portion of a jaw assembly includingfirst and second electrically-insulative bushings in accordance with anembodiment of the present disclosure;

FIG. 10B is enlarged, perspective view of the secondelectrically-insulative bushing shown in FIG. 10A;

FIG. 11A is a schematic diagram of a portion of a jaw assembly includingan electrically-insulative jaw insert in accordance with an embodimentof the present disclosure;

FIG. 11B is a schematic diagram of a portion of a jaw assembly inaccordance with an embodiment of the present disclosure;

FIG. 11C is an enlarged, cross-sectional view taken along the sectionlines 11C-11C of FIG. 11A;

FIG. 12 is an enlarged, perspective view of the electrically-insulativejaw insert shown in FIG. 11A;

FIG. 13 is an enlarged, perspective view of the firstelectrically-insulative bushing shown in FIG. 10A;

FIG. 14 is an enlarged, cross-sectional view of the jaw assembly ofFIGS. 10A and 11A, including the electrically-insulative jaw insertshown in FIG. 12, the first electrically-insulative bushing shown inFIG. 13, and the second electrically-insulative bushing shown in FIG.10B in accordance with an embodiment of the present disclosure;

FIG. 15 is an enlarged, cross-sectional view of an end-effector assemblyincluding the jaw assembly of FIG. 14 in accordance with an embodimentof the present disclosure;

FIG. 16A is a perspective view of another embodiment of anelectrically-insulative bushing in accordance with the presentdisclosure;

FIG. 16B is a perspective view of yet another embodiment of anelectrically-insulative bushing in accordance with the presentdisclosure;

FIG. 17A is a perspective view of an electrically-insulative tubularbushing in accordance with an embodiment of the present disclosure;

FIG. 17B is a perspective view of an oblong electrically-insulativebushing in accordance with an embodiment of the present disclosure;

FIG. 18 is an enlarged, cross-sectional view of a jaw assembly includingtwo of the electrically-insulative bushings shown in FIG. 16A and two ofthe electrically-insulative bushings shown in FIG. 16B in accordancewith an embodiment of the present disclosure;

FIG. 19 is an enlarged, cross-sectional view of a jaw assembly includingthe electrically-insulative tubular bushing shown in FIG. 17A and theoblong electrically-insulative bushing shown in FIG. 17B in accordancewith an embodiment of the present disclosure; and

FIG. 20 an enlarged, cross-sectional view of an end-effector assemblyincluding the jaw assembly of FIG. 19 in accordance with an embodimentof the present disclosure.

DETAILED DESCRIPTION

Hereinafter, embodiments of jaw assemblies for use in electrosurgicalinstruments and methods of manufacturing jaw assemblies of the presentdisclosure are described with reference to the accompanying drawings.Like reference numerals may refer to similar or identical elementsthroughout the description of the figures. As shown in the drawings andas used in this description, and as is traditional when referring torelative positioning on an object, the term “proximal” refers to thatportion of the apparatus, or component thereof, closer to the user andthe term “distal” refers to that portion of the apparatus, or componentthereof, farther from the user.

This description may use the phrases “in an embodiment,” “inembodiments,” “in some embodiments,” or “in other embodiments,” whichmay each refer to one or more of the same or different embodiments inaccordance with the present disclosure.

Various embodiments of the present disclosure provide electrosurgicalinstruments suitable for sealing, cauterizing, coagulating/desiccatingand/or cutting vessels and vascular tissue. Various embodiments of thepresent disclosure provide an electrosurgical forceps with anend-effector assembly including opposing jaw assemblies pivotablymounted with respect to one another. Various embodiments of the presentdisclosure provide jaw assemblies formed to meet specific tolerancerequirements for proper jaw alignment, thermal resistance, strength andrigidity. Various embodiments of the present disclosure provide methodsof manufacturing jaw assembly components of end-effector assemblies foruse in electrosurgical instruments, including without limitation,bipolar forceps.

Embodiments of the presently-disclosed electrosurgical forceps may besuitable for utilization in endoscopic surgical procedures and/orsuitable for utilization in open surgical applications. Embodiments ofthe presently-disclosed bipolar forceps may be implemented usingelectromagnetic radiation at microwave frequencies, radio frequencies(RF) or at other frequencies.

Although the following description describes the use of an endoscopicbipolar forceps, the teachings of the present disclosure may also applyto a variety of electrosurgical devices that include jaw assemblies.

In FIG. 1, an embodiment of an endoscopic bipolar forceps 10 is shownfor use with various surgical procedures and generally includes ahousing 20, a handle assembly 30, a rotatable assembly 80, a triggerassembly 70 and an end-effector assembly 22 that mutually cooperate tograsp, seal and/or divide tissue, e.g., tubular vessels and vasculartissue (not shown). Although FIG. 1 depicts a bipolar forceps 10 for usein connection with endoscopic surgical procedures, the teachings of thepresent disclosure may also apply to more traditional open surgicalprocedures. For the purposes herein, the forceps 10 is described interms of an endoscopic instrument; however, an open version of theforceps (e.g., bipolar forceps 200 shown in FIG. 2) may also include thesame or similar operating components and features as described below.

Forceps 10 includes a shaft 12 having a distal end 16 configured tomechanically engage the end-effector assembly 22 and a proximal end 14configured to mechanically engage the housing 20. In some embodiments,the shaft 12 has a length from the proximal side of the handle assembly30 to the distal side of the forceps 10 in a range of about 7centimeters to about 44 centimeters. End-effector assembly 22 may beselectively and releaseably engageable with the distal end 16 of theshaft 12, and/or the proximal end 14 of the shaft 12 may be selectivelyand releaseably engageable with the housing 20 and the handle assembly30.

The proximal end 14 of the shaft 12 is received within the housing 20,and connections relating thereto are disclosed in commonly assigned U.S.Pat. No. 7,150,097 entitled “METHOD OF MANUFACTURING JAW ASSEMBLY FORVESSEL SEALER AND DIVIDER”, commonly assigned U.S. Pat. No. 7,156,846entitled “VESSEL SEALER AND DIVIDER FOR USE WITH SMALL TROCARS ANDCANNULAS”, commonly assigned U.S. Pat. No. 7,597,693 entitled “VESSELSEALER AND DIVIDER FOR USE WITH SMALL TROCARS AND CANNULAS” and commonlyassigned U.S. Pat. No. 7,771,425 entitled “VESSEL SEALER AND DIVIDERHAVING A VARIABLE JAW CLAMPING MECHANISM”.

Forceps 10 includes an electrosurgical cable 15. Electrosurgical cable15 may be formed from a suitable flexible, semi-rigid or rigid cable,and may connect directly to an electrosurgical power generating source28. In some embodiments, the electrosurgical cable 15 connects theforceps 10 to a connector 17, which further operably connects theinstrument 10 to the electrosurgical power generating source 28. Cable15 may be internally divided into one or more cable leads (e.g., 325 aand 325 b shown in FIGS. 7 and 8, respectively) each of which transmitselectrosurgical energy through their respective feed paths to theend-effector assembly 22.

Electrosurgical power generating source 28 may be any generator suitablefor use with electrosurgical devices, and may be configured to providevarious frequencies of electromagnetic energy. Examples ofelectrosurgical generators that may be suitable for use as a source ofelectrosurgical energy are commercially available under the trademarksFORCE EZ™, FORCE FX™, and FORCE TRIAD™ offered by Covidien SurgicalSolutions of Boulder, Colo. Forceps 10 may alternatively be configuredas a wireless device or battery-powered.

End-effector assembly 22 generally includes a pair of opposing jawassemblies 110 and 120 pivotably mounted with respect to one another.End-effector assembly 22 may be configured as a bilateral jaw assembly,i.e., both jaw assemblies 110 and 120 move relative to one another.Alternatively, the forceps 10 may include a unilateral assembly, i.e.,the end-effector assembly 22 may include a stationary or fixed jawassembly, e.g., 120, mounted in fixed relation to the shaft 12 and apivoting jaw assembly, e.g., 110, mounted about a pivot pin 103 coupledto the stationary jaw assembly. Jaw assemblies 110 and 120 may be curvedat various angles to facilitate manipulation of tissue and/or to provideenhanced line-of-sight for accessing targeted tissues.

As shown in FIG. 1, the end-effector assembly 22 is rotatable about alongitudinal axis “A-A” through rotation, either manually or otherwise,of the rotatable assembly 80. Rotatable assembly 80 generally includestwo halves (not shown), which, when assembled about a tube of shaft 12,form a generally circular rotatable member 82. Rotatable assembly 80, orportions thereof, may be configured to house a drive assembly (notshown) and/or a knife assembly (not shown), or components thereof. Areciprocating sleeve (not shown) is slidingly disposed within the shaft12 and remotely operable by the drive assembly (not shown). Examples ofrotatable assembly embodiments, drive assembly embodiments, and knifeassembly embodiments of the forceps 10 are described in theabove-mentioned, commonly-assigned U.S. Pat. Nos. 7,150,097, 7,156,846,7,597,693 and 7,771,425.

Handle assembly 30 includes a fixed handle 50 and a movable handle 40.In some embodiments, the fixed handle 50 is integrally associated withthe housing 20, and the movable handle 40 is selectively movablerelative to the fixed handle 50. Movable handle 40 of the handleassembly 30 is ultimately connected to the drive assembly (not shown).As can be appreciated, applying force to move the movable handle 40toward the fixed handle 50 pulls the drive sleeve (not shown) proximallyto impart movement to the jaw assemblies 110 and 120 from an openposition, wherein the jaw assemblies 110 and 120 are disposed in spacedrelation relative to one another, to a clamping or closed position,wherein the jaw assemblies 110 and 120 cooperate to grasp tissuetherebetween. Examples of handle assembly embodiments of the forceps 10are described in the above-mentioned, commonly-assigned U.S. Pat. Nos.7,150,097, 7,156,846, 7,597,693 and 7,771,425.

Forceps 10 includes a switch 200 configured to permit the user toselectively activate the forceps 10 in a variety of differentorientations, i.e., multi-oriented activation. As can be appreciated,this simplifies activation. When the switch 200 is depressed,electrosurgical energy is transferred through one or more electricalleads (e.g., leads 325 a and 325 b shown in FIGS. 7 and 8, respectively)to the jaw assemblies 110 and 120. Although FIG. 1 depicts the switch200 disposed at the proximal end of the housing assembly 20, switch 200may be disposed on another part of the forceps 10 (e.g., the fixedhandle 50, rotatable member 82, etc.) or another location on the housingassembly 20.

In FIG. 2, an embodiment of an open forceps 200 is shown for use withvarious surgical procedures and generally includes a pair of opposingshafts 212 a and 212 b having an end effector assembly 230 attached tothe distal ends 216 a and 216 b thereof, respectively. End effectorassembly 230 includes a pair of opposing jaw members 232 and 234 thatare pivotably connected about a pivot pin 265 and movable relative toone another to grasp tissue. Each shaft 212 a and 212 b includes ahandle 215 and 217, respectively, disposed at the proximal end 214 a and214 b thereof, respectively. Each handle 215 and 217 defines a fingerand/or thumb hole 215 a and 217 a, respectively, therethrough forreceiving the user's finger or thumb. Finger and/or thumb holes 215 aand 217 a facilitate movement of the shafts 212 a and 212 b relative toone another to pivot the jaw members 232 and 234 from an open position,wherein the jaw members 232 and 234 are disposed in spaced relationrelative to one another, to a clamping or closed position, wherein thejaw members 232 and 234 cooperate to grasp tissue therebetween.

FIGS. 3A and 3B show a jaw assembly (shown generally as 310 in FIGS. 3Aand 3B) according to an embodiment of the present disclosure thatincludes a jaw member 311 and an electrically-conductive tissue-engagingsurface or sealing plate 312. Jaw member 311 includes a support base 319that extends distally from an arm member 313. Jaw member 311 may defineone or more apertures at least partially therethrough, e.g., pivot holesand/or pin slots or openings. In some embodiments, the jaw member 311includes an elongated angled slot 381 a and a pivot hole 386 a (shown inphantom lines in FIG. 3A) defined therethrough.

Sealing plate 312 includes an electrode tip portion 309 for contactingtissue. Electrode tip portion 309 may be monopolar or bipolar. Electrodetip portion 309 may be configured to provide a desired function, and mayinclude curves at various angles to facilitate contact with targetedtissue. Electrode tip portion 309 may include a sharp knife edge, ablunt tip, a blunt edge, paddle, hook, a ball-shaped portion, or anothershape.

FIGS. 4 through 7 show a jaw assembly 410 according to an embodiment ofthe present disclosure that includes a jaw member 111, anelectrically-conductive tissue-engaging surface or sealing plate 160,and a non-electrically conductive member 419. In some embodiments, thesealing plate 160 may include an electrode tip portion, e.g., similar tothe electrode tip portion 309 of the sealing plate 312 shown in FIG. 3.Non-electrically conductive member 419 is generally formed of anelectrically insulative material and defines a first portion 412 (FIG.5) configured to engage the sealing plate 160 and a second portion 414(FIG. 5) configured to engage the jaw member 111, or component thereof(e.g., support base 119 shown in FIG. 7). In some embodiments, thesupport base 119 includes an inner-facing surface 118 (FIG. 7)configured to support at least a portion of the non-electricallyconductive member 419 thereon.

As shown in FIGS. 5 and 7, the sealing plate 160 includes aknife-channel portion 115 a, the non-electrically conductive member 419includes a knife-channel portion 415 a, and the jaw member 111 includesa central channel 105 a, which when assembled, form alongitudinally-oriented slot or knife channel 515 a (FIG. 5) definedtherethrough for reciprocation of a knife blade (not shown). In someembodiments, as shown in FIG. 5, the bottom of the knife channel 515 amay extend below a plane (not shown) containing the upper surface of thejaw member 111, e.g. to improve strength and/or rigidity of the jawassembly 410. In alternative embodiments (not necessarily shown), thebottom of the knife channel 515 a may be disposed above a plane (notshown) containing the upper surface of the jaw member 111, e.g.,depending upon the height of the knife blade (not shown) and/or thematerial properties of the material(s) used to form the non-electricallyconductive member 419.

Jaw member 111, which is described in more detail later in thisdescription, may define one or more apertures at least partiallytherethrough, e.g., pivot holes and/or pin slots or openings. Anembodiment of a jaw member, such as the jaw assembly 111 of FIGS. 4 and5, in accordance with the present disclosure, is shown in more detail inFIG. 7. It will be understood, however, that other jaw memberembodiments may also be used. In some embodiments, as shown in FIGS. 4and 7, the jaw member 111 includes an elongated angled slot 181 a and apivot hole 186 a defined therethrough.

An embodiment of a sealing plate, such as sealing plate 160 of FIGS. 4and 5, in accordance with the present disclosure, is shown in moredetail in FIG. 7. It will be understood, however, that other sealingplate embodiments may also be used. Sealing plate 160 generally includesa first portion 161 and a second portion 162, and may include anelectrode tip portion (e.g., electrode tip portion 309 shown in FIG. 3).First portion 161 and the second portion 162 of the sealing plate 160are at least partially separated by a longitudinally-oriented slot orknife-channel portion 115 a defined therebetween.

Non-electrically conductive member 419 is configured to electricallyisolate, at least in part, the sealing plate 160 from the jaw member111. Non-electrically conductive member 419 includes a knife-channelportion 415 a defined therein which extends longitudinally along aportion of the non-electrically conductive member 419 and which alignsin vertical registration with the knife-channel portion 115 a defined inthe sealing plate 160 to facilitate translation of the distal end of theknife (not shown) therethrough.

Non-electrically conductive member 419 may be formed of any suitableelectrically insulative material, e.g., non-electrically conductivecomposite materials, with desired material characteristics. In someembodiments, non-electrically conductive member 419 is formed ofnon-electrically conductive ceramic, and may provide enhanced thermalresistance, strength, and/or rigidity of the jaw assembly 410. Inalternative embodiments not shown, non-electrically conductive member419 may be formed of a combination of electrically-conductive materials,partially electrically-conductive materials, and/or non-electricallyconductive materials. Non-electrically conductive member 419 may beformed as a multi-layer configuration of materials. Non-electricallyconductive member 419 may be formed by any suitable process, e.g.,injection molding, ceramic injection molding (CIM), or compressionmolding.

As shown in FIGS. 5 and 7, the non-electrically conductive member 419includes a body 418 defining a first lateral side portion 446 having afirst length “L1”, a second lateral side portion 447 having a secondlength “L2”, and an upper portion 445 disposed between the first andsecond lateral side portions 446 and 447, respectively. First and secondlateral side portions 446 and 447, respectively, are joined at one endby an apex 449 (FIG. 7) disposed at the distal end of the body 418 andspaced apart at opposing ends to define an opening 448 (FIG. 5)therebetween. Upper portion 445 includes a generally U-shaped wallportion 444 defining the knife-channel portion 415 a. As shown in FIG.5, at least a portion of the wall portion 444 is disposed within thecentral channel 105 a of the jaw member 111.

The first and second lengths “L1” and “L2” of the first and secondlateral side portions 446 and 447, respectively, may depend on theconfiguration of the jaw member 111, or component thereof (e.g., supportbase 119), and/or the configuration of the sealing plate 160. In someembodiments, as shown in FIG. 7, the first length of the first lateralside portion 446 is different than the second length of the secondlateral side portion 447. In alternative embodiments not shown, thefirst and second lengths “L1” and “L2” of the first and second lateralside portions 446 and 447, respectively, may be substantially the same,e.g., depending on the configuration of the jaw member and/or theconfiguration of the sealing plate.

As shown in FIG. 5, the first portion 412 of the non-electricallyconductive member 419 includes a first surface 413 and a shoulder region416 extending outwardly beyond the first surface 413 along at least aportion of the first lateral side portion 446. In some embodiments, asshown in FIG. 5, the first surface 413 is configured to support thefirst portion 161 of the sealing plate 160 and to support at least aportion of the second portion 162 of the sealing plate 160.

First surface 413 is configured to support at least a portion of thesealing plate 160, and may be a substantially flat surface. Inalternative embodiments not shown, the non-electrically conductivemember 419 may include texturized surface areas disposed on, orotherwise associated with, the first surface 413 on either one or bothsides of the longitudinally-oriented knife-channel portion 415 a. Thetexturized surface areas may include any suitable type of texturizedsurface or pattern formed by any suitable process.

Sealing plate 160 may be affixed atop the first surface 413 of the firstportion 412 of the non-electrically conductive member 419 in anysuitable manner, e.g., joined by brazing and/or adhesive bonding. Asshown in FIG. 5, material 450, e.g., brazing material or adhesivematerial, may be disposed between the sealing plate 160 and thenon-electrically conductive member 419, e.g., to facilitate assemblyand/or provide strength and rigidity.

Shoulder region 416 may be configured to provide strength and/orrigidity. Shoulder region 416 generally includes an inner wall 415located to facilitate the proper alignment of the sealing plate 160,e.g., to vertically align the knife-channel portion 115 a of the sealingplate 160 in relation to the knife-channel portion 415 a of thenon-electrically conductive member 419, such as during assembly of thejaw member 410. In some embodiments, as shown in FIG. 5, the inner wall415 is configured to engage a side portion of the second portion 162 ofthe sealing plate 160. The shape and size of the shoulder region 416 maybe varied from the configuration depicted in FIG. 5.

In some embodiments, as shown in FIG. 5, the first portion 412 of thenon-electrically conductive member 419 includes a flange 417 extendingoutwardly beyond the first surface 413 along at least a portion of thesecond lateral side portion 447, e.g., to facilitate the positioningand/or secure attachment of the sealing plate 160 to thenon-electrically conductive member 419. Flange 417 is configured toengage a recess or channel 165 defined in the second portion 162 of thesealing plate 160. The shape, size and location of the flange 417 may bevaried from the configuration depicted in FIG. 5.

Second portion 414 of the non-electrically conductive member 419includes the inner surface of the first lateral side portion 446, innersurface of the second lateral side portion 447, and the inner surface ofthe upper portion 445 disposed between the first and second lateral sideportions 446 and 447, respectively. The opening 448 defined by the innersurfaces of the first and second lateral side portions 446, 447 and theupper portion 445 is configured to receive the jaw member 111 therein.As shown in FIG. 5, material 450, e.g., brazing material or adhesivematerial, may be disposed between the jaw member 111 and the innersurfaces of the first and second lateral side portions 446, 447 and theupper portion 445, e.g., to facilitate assembly and/or provide strengthand rigidity. In alternative embodiments not shown, the inner surface ofthe first lateral side portion 446, inner surface of the second lateralside portion 447, and/or the inner surface of the upper portion 445 mayinclude detents, tongue and groove interfaces, locking tabs, adhesiveports, etc., utilized either alone or in combination for assemblypurposes.

Sealing plate 160 and the non-electrically conductive member 419, whenassembled, including the second portion 162 of the sealing plate 160disposed adjacent to the shoulder region 416 of the non-electricallyconductive member 419, and/or the flange 417 of the non-electricallyconductive member 419 received in the channel 165 of the first portion161 of the sealing plate 160, may increase stability of the knifechannel and/or provide increased jaw assembly integrity, and/or mayfacilitate and/or improve knife-blade reciprocation, and/or may resultin improved tissue-cutting capabilities.

Non-electrically conductive member 419 may be used for joining togethersealing plates and support bases of jaw members of varied geometries,e.g., lengths and curvatures, or having additional, fewer, or differentfeatures than the first and second support bases 119, 129, such thatvariously-configured jaw assemblies may be fabricated and assembled intovarious end-effector configurations, e.g., depending upon design ofspecialized electrosurgical instruments.

FIG. 6 shows a fixture assembly (shown generally as 600 in FIG. 6)according to an embodiment of the present disclosure that includes afirst fixture member 601 and a second fixture member 602. Fixtureassembly 600 is adapted to releaseably, securely hold the jaw member111, the sealing plate 160, and the non-electrically conductive member419 in position relative to one another to facilitate brazing, bonding,or otherwise joining, the jaw member 111, the sealing plate 160, and thenon-electrically conductive member 419.

First fixture member 601 is configured to releaseably engage an upperportion of the sealing plate 160 and at least a portion of the firstportion 412 of the non-electrically conductive member 419. First fixturemember 601 may include one or more securing mechanisms (e.g., twosecuring mechanisms 611 and 612 shown in FIG. 6) adapted to securelyhold the sealing plate 160 in engagement with the first portion 412 ofthe non-electrically conductive member 419, e.g., to achieve desiredalignment conditions. In some embodiments, as shown in FIG. 6, the firstfixture member 601 includes a first securing mechanism 611, e.g.,adapted to securely hold the first portion 161 of the sealing plate 160in engagement with the non-electrically conductive member 419, and asecond securing mechanism 612, e.g., adapted to securely hold the secondportion 162 of the sealing plate 160 in engagement with thenon-electrically conductive member 419.

Second fixture member 602 is configured to releaseably engage a bottomportion of the jaw member 111, and may be configured to releaseablyengage at least a portion of the second portion 414 of thenon-electrically conductive member 419. In some embodiments, as shown inFIG. 6, the second fixture member 602 includes a third securingmechanism 613, e.g., adapted to securely hold the jaw member 111 inengagement with the non-electrically conductive member 419. First,second, and third securing mechanisms 611, 612 and 613, respectively,may be springs, clips or other releasable fasteners. In someembodiments, the first, second, and third securing mechanisms 611, 612and 613, respectively, may include magnets, vacuum and/or compressedair, and/or adhesive.

FIG. 7 shows components of a jaw assembly (shown generally as 700 inFIG. 7) according to an embodiment of the present disclosure thatincludes the jaw assembly 410 shown in FIG. 5. FIG. 8 shows componentsof a jaw assembly (shown generally as 800 in FIG. 8) according to anembodiment of the present disclosure. Jaw assemblies 700 and 800 mayinclude additional, fewer, or different components than shown in FIGS. 7and 8, respectively, depending upon a particular purpose or to achieve adesired result.

As shown in FIG. 7, jaw member 111 includes the support base 119(hereinafter referred to as the “first support base”) that extendsdistally from the arm member 113 (hereinafter referred to as the “firstarm member”). First arm member 113 and the first support base 119 aregenerally formed from metal, e.g., steel, and may include non-metalelements. First arm member 113 and the first support base 119 may beformed from any suitable material or combination of materials. Jawmember 111 may be formed by any suitable process, e.g., machining,stamping, electrical discharge machining (EDM), forging, casting,injection molding, metal injection molding (MIM), and/or fineblanking.

In some embodiments, the first arm member 113 and the first support base119 are separately fabricated and each includes an engagement structure(not shown) configured for attachment to one another. During amanufacturing process, the engagement structure of the first arm member113 is welded, joined or otherwise attached to the engagement structureof the first support base 119 along an interface 3 formed therebetweenwhen the respective engagement structures (not shown) are placed incontact with one another, thereby forming the jaw member 111(hereinafter referred to as the “first jaw member”). Examples ofengagement structure embodiments are described in commonly-assigned U.S.patent application Ser. No. 13/243,628 filed on Sep. 23, 2011, entitled“END-EFFECTOR ASSEMBLIES FOR ELECTROSURGICAL INSTRUMENTS AND METHODS OFMANUFACTURING JAW ASSEMBLY COMPONENTS OF END-EFFECTOR ASSEMBLIES”.

First arm member 113 may define one or more apertures at least partiallytherethrough, e.g., pivot holes and/or pin slots or openings. In someembodiments, as shown in FIG. 7, the first arm member 113 includes anelongated angled slot 181 a and a pivot hole 186 a defined therethrough.The shape, size and spacing of the slot 181 a and the pivot hole 186 amay be varied from the configuration depicted in FIG. 7. First armmember 113 may include additional, fewer, or different apertures thanshown in FIG. 7.

First support base 119 together with the non-electrically conductivemember 419 may be encapsulated by the sealing plate 160 and an outerhousing 114 having a cavity 114 a defined therein. In some embodiments,the outer housing 114 is formed, at least in part, of an electricallynon-conductive or substantially electrically non-conductive material.Cavity 114 a may be configured to at least partially encapsulate and/orsecurely engage the first support base 119, the non-electricallyconductive member 419 and/or the sealing plate 160.

Examples of sealing plate 160, outer housing 114, and knife bladeembodiments are disclosed in commonly assigned International ApplicationSerial No. PCT/US01/11412 filed on Apr. 6, 2001, entitled“ELECTROSURGICAL INSTRUMENT WHICH REDUCES COLLATERAL DAMAGE TO ADJACENTTISSUE”, and commonly assigned International Application Serial No.PCT/US01/11411 filed on Apr. 6, 2001, entitled “ELECTROSURGICALINSTRUMENT REDUCING FLASHOVER”.

In some embodiments, jaw assembly 111 is connected to a first electricallead 325 a. Lead 325 a, in turn, is electrically coupled with anelectrosurgical energy source (e.g., 28 shown in FIG. 1). In someembodiments, lead 325 a terminates within the outer housing 114 and isconfigured to electro-mechanically couple to the sealing plate 160 byvirtue of a crimp-like connection (not shown).

As shown in FIG. 8, jaw assembly 800 includes similar elements to jawassembly 700 of FIG. 7, such as an outer housing 124 having a cavity 124a defined therein and a jaw assembly 420 including an non-electricallyconductive member 429 configured to support an electrically-conductivetissue-engaging surface or sealing plate 150 thereon. Cavity 124 a maybe configured to at least partially encapsulate and/or securely engagethe support base 129, the non-electrically conductive member 429, and/orthe sealing plate 150.

Second jaw member 121 includes a second support base 129 extendingdistally from a second arm member 123. Second arm member 123 and thesecond support base 129 may be formed from any suitable materials, e.g.,metal, or combination of materials. Second arm member 123 may define oneor more apertures at least partially therethrough, e.g., pivot holesand/or pin slots or openings. In some embodiments, as shown in FIG. 8,the second arm member 123 includes an elongated angled slot 181 b and apivot hole 186 b defined therethrough. In alternative embodiments notshown, the second arm member 123 may include other apertures defined atleast partially therethrough.

Similar to like elements of jaw assembly 410, when assembled, thesealing plate 150 and the non-electrically conductive member 429, whenassembled, include respective longitudinally-oriented knife channels 115b and 415 b defined therethrough for reciprocation of a knife blade (notshown). Sealing plate 150 and the non-electrically conductive member429, when assembled, including the second portion 152 of the sealingplate 150 disposed adjacent to the shoulder region 426 of thenon-electrically conductive member 429, and/or the flange 427 of thenon-electrically conductive member 429 received in the channel 155 ofthe first portion 151 of the sealing plate 160, may increase stabilityof the knife channel and/or provide increased jaw assembly integrity,and/or may facilitate and/or improve knife-blade reciprocation, and/ormay result in improved tissue-cutting capabilities. Jaw assembly 420shown in FIG. 8 is similar to the jaw assembly 410 shown in FIG. 7, andfurther description of the like elements is omitted in the interests ofbrevity.

When the jaw assemblies 700 and 800 are closed about tissue,knife-channel portions 115 a, 415 a and 115 b, 415 b form a completeknife channel (not shown) to allow longitudinal extension of the knifeblade (not shown) in a distal fashion to sever tissue along a tissueseal. In alternative embodiments, the knife channel may be completelydisposed in one of the two jaw assemblies, e.g., jaw assembly 800,depending upon a particular purpose. Jaw assembly 800 may be assembledin a similar manner as described above with respect to jaw assembly 700.

As shown in FIG. 8, jaw assembly 800 is connected to an electrical lead325 b. Lead 325 b, in turn, is electrically coupled to anelectrosurgical energy source (e.g., 28 shown in FIG. 1). In someembodiments, lead 325 b terminates within the outer housing 124 and isconfigured to electro-mechanically couple to the sealing plate 150 byvirtue of a crimp-like connection (not shown). Leads 325 a (FIG. 7) and325 b may allow a user to selectively supply either bipolar or monopolarelectrosurgical energy to the jaw assemblies 700 and 800 as neededduring surgery.

In some embodiments, as shown in FIG. 8, jaw assembly 800 includes aseries of stop members 90 disposed on the inner-facing surfaces of thefirst portion 151 and the second portion 152 or the sealing plate 150.Stop members 90 may be configured to facilitate and/or enhance thegripping and manipulation of tissue and to control the gap distance (notshown) between opposing jaw assemblies 700 and 800 during the sealingand cutting of tissue. Stop members 90 of varied configurations may beemployed on one or both jaw assemblies 700 and 800 depending upon aparticular purpose or to achieve a desired result. Examples of stopmember embodiments as well as various manufacturing and assemblingprocesses for attaching and/or affixing the stop members 90 to thesealing plate surfaces are described in commonly-assigned InternationalApplication Serial No. PCT/US01/11413 filed on Apr. 6, 2001, entitled“VESSEL SEALER AND DIVIDER WITH NON-CONDUCTIVE STOP MEMBERS”. In somevariations of stop members, compatible with any of the aboveembodiments, stop members may be printed, patterned, applied, orotherwise deposited using a direct write process, such as by amicro-capillary system, e.g., MICROPEN® technology, or any othersuitable material deposition technology.

In alternative embodiments shown in FIGS. 10A through 20, compatiblewith any of the above embodiments of arm members and support bases forassembly into jaw assembly configurations, an electrically-insulativebushing may be used to electrically isolate the opposing jaw membersfrom one another, wherein a configuration of one or moreelectrically-insulative bushings may be associated with either or bothjaw members.

Hereinafter, a method of manufacturing a jaw assembly is described withreference to FIG. 9. It is to be understood that the steps of the methodprovided herein may be performed in combination and in a different orderthan presented herein without departing from the scope of thedisclosure.

FIG. 9 is a flowchart illustrating a method of manufacturing a jawassembly 410 according to an embodiment of the present disclosure. Instep 910, an electrically-conductive tissue-engaging structure 160 isprovided.

In step 920, a jaw member 111 including a support base 119 is provided.In some embodiments, the jaw member 111 includes an arm member 113,wherein the support base 119 extends distally from the arm member 113.Arm member 113 may include an elongated angled slot 181 a and a pivothole 186 a defined therethrough. In some embodiments, the support base119 includes an inner-facing surface 118 configured to support at leasta portion of a non-electrically conductive member 419 associated withthe jaw assembly 410.

In step 930, a non-electrically conductive member 419 adapted toelectrically isolate the electrically-conductive tissue-engagingstructure 160 from the jaw member 111 is provided. Non-electricallyconductive member 419 includes a first portion 412 configured to engagethe electrically-conductive tissue-engaging structure 160 and a secondportion 414 configured to engage the support base 119 of the jaw member111.

In some embodiments, the non-electrically conductive member 419 includesa body 418 defining a first lateral side portion 446 and a secondlateral side portion 447. First portion 412 of the non-electricallyconductive member 419 may include a first surface 413 and a shoulderregion 416 extending outwardly beyond the first surface 413 along atleast a portion of the first lateral side portion 446.

In step 940, a fixture assembly 600 is provided. Fixture assembly 600 isconfigured to hold the electrically-conductive tissue-engaging structure160 in position with respect to the first portion 412 of thenon-electrically conductive member 419 and to hold the support base 119in position with respect to the second portion 414 of thenon-electrically conductive member 419. In some embodiments, the fixtureassembly 600 includes a first fixture member 601 and a second fixturemember 602.

In step 950, a brazing process (or other suitable bonding process) isperformed to join the electrically-conductive tissue-engaging structure,non-electrically conductive member and the jaw member using the fixtureassembly, thereby forming a jaw assembly 410. Fixture assembly 600 isadapted to releaseably and securely hold the jaw member, theelectrically-conductive tissue-engaging structure, and thenon-electrically conductive member in position relative to one anotherto facilitate the brazing process.

In step 960, the jaw assembly 410 is removed from the fixture assembly600. It will be appreciated that additional manufacturing steps may beundertaken after the step 950, prior to the removal of the jaw assembly410 from the fixture assembly 600 in the step 960.

The presently disclosed method of manufacturing a jaw assembly 410 mayfurther include the step of positioning the electrically-conductivetissue-engaging structure 160 in relation to an inner wall 415 of theshoulder region 416 of the non-electrically conductive member 419.

FIG. 10A shows a portion of a jaw assembly (shown generally as 1000 inFIG. 10A) in accordance with an embodiment of the present disclosurethat includes a jaw member 1420 including a support base 1019 thatextends distally from an arm member 1013. Arm member 1013 generallydefines one or more apertures at least partially therethrough. In someembodiments, as shown in FIG. 10A, the arm member 1013 includes a firstopening 1091 and a second opening or slot 1096 defined therethrough. Theshape, size and location of the first opening 1091 and the secondopening or slot 1096 may be varied from the configuration depicted inFIG. 10A. In alternative embodiments not shown, the jaw assembly 1000may include additional, fewer, or different apertures than shown in FIG.10A.

In some embodiments, as shown in FIG. 10A, at least a portion of a firstelectrically-insulative bushing 1300, which is shown in more detail inFIG. 13, is disposed within the pivot hole 1091 defining a pivot hole1386 a therethrough, and at least a portion of a secondelectrically-insulative bushing 1076, which is shown in more detail inFIG. 10B, is disposed within the second opening or slot 1096.

In FIG. 10B, the second electrically-insulative bushing 1070 of FIG. 10Ais shown and includes a first portion 1075 including a first surface1076, a second portion 1078 coupled to the first portion 1075, and anelongated slot 1081 a defined therethrough. Second portion 1078 of thesecond electrically-insulative bushing 1070 has a length “L3”. As shownin FIGS. 10A and 10B, the second portion 1078 of theelectrically-insulative bushing 1070 includes a surface 1077. In someembodiments, the length “L3” of the second portion 1078 of the secondelectrically-insulative bushing 1070 is longer than the length “L6” ofthe arm member 1013 shown in FIG. 11C, e.g., to facilitate alignmentand/or mating engagement with the electrically-insulative jaw insert1200.

FIG. 11A shows a portion of a jaw assembly (shown generally as 1000 inFIG. 11A) that includes an electrically-insulative jaw insert 1200 inaccordance with an embodiment of the present disclosure shown with thefirst and second electrically-insulative bushings 1300 and 1070,respectively, of FIG. 10A. The electrically-insulative jaw insert 1200may be attached to the jaw assembly 1000 in any suitable way. In someembodiments, the electrically-insulative jaw insert 1200 may be attachedto the jaw assembly 1000 using an adhesive having suitable bondingcharacteristics. The first electrically-insulative bushing 1300 (FIG.13) is disposed in part within the first opening 1291 defined in theinsert 1200, and the second electrically-insulative bushing 1070 isdisposed in part within the second opening or slot 1296 defined in theinsert 1200.

FIG. 11B shows a structural insert 1140 that includes a member 1113defining a first opening 1191 and a second opening or slot 1196therethrough. In some embodiments, the electrically-insulative bushing1070, the electrically-insulative jaw insert 1200 and/or theelectrically-insulative bushing 1300 (or other bushings) may be attachedto the structural insert 1140. In some embodiments the first opening1191 is configured to receive a portion of the electrically-insulativejaw insert 1200, and the second opening or slot 1196 may be configuredto receive a portion of the electrically-insulative bushing 1070.

FIG. 11C shows an enlarged, cross-sectional view of a portion of the jawassembly 1000 of FIG. 11A. In some embodiments, as shown in FIG. 11C,the first electrically-insulative bushing 1300 extends through theopening 1091 defined in the arm member 1013 of the jaw member 1420 (FIG.11A) and the second opening or slot 1296 defined in the insert body 1201of the insert 1200.

As best shown in FIG. 12, the electrically-insulative jaw insert 1200includes an insert body 1201 defining a first opening 1291 and a secondopening or slot 1296 therethrough. Insert 1200 may be formed from anysuitable non-electrically conductive material. In some embodiments, theinsert 1200 may include ceramic or any of a variety of suitablenon-electrically conductive materials such as polymeric materials, e.g.,plastics, and/or other insulative materials. In other embodiments, othernon-electrically conductive synthetic and/or natural materials havingsuitable weight, strength, cost and/or other characteristics may be usedfor the insert 1200. In alternative embodiments not shown, the insertbody 1201 may include other apertures defined at least partiallytherethrough.

In some embodiments, as shown in FIGS. 11A and 12, the insert body 1201is substantially flat and planar. As shown in FIG. 11A, at least aportion of the first electrically-insulative bushing 1300 is disposedwithin the first opening 1291 of the insert body 1201 defining a pivothole 1186 b, and at least a portion of the secondelectrically-insulative bushing 1070 is disposed in the second openingor slot 1296 of the insert body 1201 defining an elongated angled slot1181 b therethrough.

FIG. 13 shows an electrically-insulative bushing 1300 in accordance withan embodiment of the present disclosure. Electrically-insulative bushing1300 includes a first portion 1301, a second portion 1302, and anaperture or opening 1386 defined therethrough. First portion 1301includes a first surface 1376 and an opposite second surface 1378.Second portion 1302 is coupled at one end to the second surface 1375 ofthe first portion 1301. Second portion 1302 includes a first surface1377. As shown in FIG. 13, the second portion 1302 of theelectrically-insulative bushing 1300 has a length “L3”.

FIG. 14 shows a cross-sectional view of the jaw assembly 1000 of FIG.10A. Jaw assembly 1000 includes the electrically-insulative jaw insert1200 of FIG. 12, the first electrically-insulative bushing 1300 of FIG.13, and the second electrically-insulative bushing 1070 of FIG. 10B.Insert 1200 provides electrical isolation between a first lateral face1014 of the arm member 1013 and component(s) of a mating jaw assembly.In some embodiments, the first surface 1376 of the first portion 1301 ofthe first electrically-insulative bushing 1300 and the first surface1076 of the first portion 1075 of the second electrically-insulativebushing 1070 may provide electrical isolation between a second lateralface 1015 of the arm member 1013 and component(s) of a mating jawassembly.

In some embodiments, the jaw assembly 1000 may be provided with anon-electrically isolated insert (e.g., 1113 shown in FIG. 15). Thisconfiguration provides an alternative way to electrically isolate theupper and lower jaw assemblies, e.g., as opposed to the embodiment shownin FIGS. 4-8, which utilizes an isolated sealing plate 160. With the useof a non-electrically isolated insert 1113, an isolated sealing plate160 is not required, and the distal end of the jaw member 1420 may beentirely or selectively (e.g., by coating) electrically active.

FIG. 15 shows a cross-sectional view of an end-effector assembly (showngenerally as 1500 in FIG. 15) including the jaw member 1420 inaccordance with an embodiment of the present disclosure. Arm member 1013and the support base 1019 of the jaw member 1420 of the lower jawassembly are electrically-isolated from the opposing arm member 2113 ofthe upper jaw assembly (partially shown in FIG. 15) by the firstelectrically-insulative bushing 1300 and the secondelectrically-insulative bushing 1070. Arm member 1013 and the supportbase 1019 of the jaw member 1420 of the lower jaw assembly areelectrically-isolated from shafts 1505 and 1508 by the insert 1200, andelectrically-isolated from pins 1503 and 1504 by the firstelectrically-insulative bushing 1300 and the secondelectrically-insulative bushing 1070.

FIG. 16A shows an electrically-insulative bushing 1600 in accordancewith an embodiment of the present disclosure. Electrically-insulativebushing 1600 includes a first portion 1601, a second portion 1602coupled to the first portion 1601, and an aperture or opening 1686defined therethrough. Second portion 1602 of the electrically-insulativebushing 1600 has a length “L4”. In some embodiments, the length “L4” ofthe second portion 1602 of the electrically-insulative bushing 1600shown in FIG. 16A is approximately one-half or less than the length “L3”of the second portion 1302 of the electrically-insulative bushing 1300of FIG. 13.

FIG. 16B shows an electrically-insulative bushing 1610 in accordancewith an embodiment of the present disclosure. Electrically-insulativebushing 1610 includes a first portion 1611, a second portion 1612coupled to the first portion 1611, and an elongated slot 1696 definedtherethrough. In some embodiments, as shown in FIG. 16B, the secondportion 1602 of the electrically-insulative bushing 1600 has a length“L4”.

FIG. 17A is a perspective view of electrically-insulative tubularbushing 1700 in accordance with an embodiment of the present disclosure.Electrically-insulative tubular bushing 1700 has a substantiallycylindrical shape and defines an aperture or opening 1786 therethrough.As shown in FIG. 17A, the electrically-insulative tubular bushing 1700has a length “L5”. In some embodiments, the length “L5” of theelectrically-insulative tubular bushing 1700 shown in FIG. 17A issubstantially equal to or greater than the length “L3” of the secondportion 1302 of the first electrically-insulative bushing 1300 of FIG.13. Although the electrically-insulative tubular bushing 1700 shown inFIG. 17A has a substantially cylindrical shape, other suitable shapesmay be utilized.

FIG. 17B shows an oblong electrically-insulative bushing 1710 inaccordance with an embodiment of the present disclosure.Electrically-insulative bushing 1710 includes a body 1712 and anelongated slot 1796 defined therethrough. Body 1712 of theelectrically-insulative bushing 1710 has a length “L5”.

FIG. 18 shows a portion of a jaw assembly (shown generally as 1800 inFIG. 18) in accordance with an embodiment of the present disclosure thatincludes the jaw member 1420 including a support base 1019 that extendsdistally from an arm member 1013. Jaw assembly 1800 includes two of thebushings 1600 and two of the bushings 1610, shown in FIGS. 16A and 16B,respectively, disposed in axial alignment with one another on oppositelateral sides of the arm member 1013. The bushings 1600 and 1610 may beattached to the arm member 1013 in any suitable way. In someembodiments, the bushings 1600 and 1610 may be attached to the armmember 1013 using an adhesive 1821 having suitable bondingcharacteristics. In alternative embodiments not shown, the jaw assembly1800 may be used in the end effector assembly 1500 of FIG. 15, i.e., inlieu of the jaw assembly 1000.

FIG. 19 shows a portion of a jaw assembly (shown generally as 1900 inFIG. 19) including the jaw member 1420 in accordance with an embodimentof the present disclosure. Jaw assembly 1900 includes two of theelectrically-insulative jaw insert 1200. Jaw assembly 1900 includes thetubular bushing 1700 of FIG. 17A disposed in the first opening 1291defined in the arm member 1013 of the jaw member 1420, and the oblongbushing 1710 of FIG. 17B disposed in second opening or slot 1296 definedin the arm member 1013. In alternative embodiments not shown, the jawassembly 1900 may be used in the end effector assembly 1500 of FIG. 15,i.e., in lieu of the jaw assembly 1000.

FIG. 20 shows a cross-sectional view of an end-effector assembly (showngenerally as 2000 in FIG. 20) in accordance with an embodiment of thepresent disclosure that includes the jaw member 1420 including a supportbase 1019 that extends distally from an arm member 1013. Arm member 1013is electrically-isolated from the pins 2003 and 2004 and from theopposing arm member 2113 by the first electrically-insulative bushing1300 and the second electrically-insulative bushing 1070. Arm member1013 is electrically-isolated from tubes 2005 and 2008 by forming tube2005 from a suitable non-electrically conductive material.

In any of the above-described embodiments, e.g., as shown in FIGS. 10Athrough 20, brazing or other suitable bonding methods may used. Anysuitable fixture may be used, e.g., fixture assembly 600 shown in FIG.6, in connection with brazing and/or adhesive bonding, or other suitablebonding process.

The above-described bipolar forceps is capable of directing energy intotissue, and may be suitable for use in a variety of procedures andoperations. The above-described end-effector embodiments may utilizeboth mechanical clamping action and electrical energy to effecthemostasis by heating tissue and blood vessels to coagulate, cauterize,cut and/or seal tissue. The jaw assemblies may be either unilateral orbilateral. The above-described bipolar forceps embodiments may besuitable for utilization with endoscopic surgical procedures and/orhand-assisted, endoscopic and laparoscopic surgical procedures. Theabove-described bipolar forceps embodiments may be suitable forutilization in open surgical applications.

The above-described method of manufacturing a jaw assembly may result inthe formation of jaw assemblies that meet specific tolerancerequirements for proper jaw alignment and other tightly-toleranced jawassembly features. The above-described method of manufacturing a jawassembly may provide improved thermal resistance, strength and rigidityof jaw assemblies using lower cost technologies.

The above-described non-electrically conductive members may be used forjoining together sealing plates and support bases of jaw members ofvaried geometries, e.g., lengths and curvatures, such thatvariously-configured jaw assemblies may be fabricated and assembled intovarious end-effector configurations, e.g., depending upon design ofspecialized electrosurgical instruments.

Although embodiments have been described in detail with reference to theaccompanying drawings for the purpose of illustration and description,it is to be understood that the inventive processes and apparatus arenot to be construed as limited thereby. It will be apparent to those ofordinary skill in the art that various modifications to the foregoingembodiments may be made without departing from the scope of thedisclosure.

What is claimed is:
 1. A jaw assembly comprising: first and second jawmembers, each of the first and second jaw members including: anelectrically-conductive tissue-engaging structure; an arm member; asupport base extending from the arm member; and a non-electricallyconductive member including a first portion configured to engage theelectrically-conductive tissue-engaging structure and a second portionconfigured to engage the support base, the non-electrically conductivemember adapted to electrically isolate the electrically-conductivetissue-engaging structure from the support base, wherein theelectrically-conductive tissue-engaging structure and thenon-electrically conductive member cooperatively define alongitudinally-oriented knife channel therethrough; an electricallyinsulative jaw insert attached to one of the arm members; and anelectrically insulative bushing having a first part and a second part,the first part larger than the second part and positioned between thejaw members and configured to electrically isolate the first jaw memberfrom the second jaw member, the second part disposed in the electricallyinsulative jaw insert.
 2. The jaw assembly of claim 1, wherein theelectrically-conductive tissue-engaging structure includes a firstportion and a second portion, the first and second portions at leastpartially separated by the longitudinally-oriented knife channel.
 3. Thejaw assembly of claim 1, wherein the non-electrically conductive memberincludes a body defining a first lateral side portion having a firstlength and a second lateral side portion having a second length.
 4. Thejaw assembly of claim 3, wherein the first and second lateral sideportions are joined at one end by an apex disposed at a distal end ofthe body and spaced apart at opposing ends to define an openingtherebetween.
 5. The jaw assembly of claim 4, wherein the opening isconfigured to receive at least a portion of the support base of thecorresponding jaw member therein.
 6. The jaw assembly of claim 3,wherein the non-electrically conductive member further includes an upperportion disposed between the first and second lateral side portions. 7.The jaw assembly of claim 6, wherein the upper portion includes aU-shaped wall portion that defines the longitudinally-oriented knifechannel.
 8. An end-effector assembly, comprising: opposing first andsecond jaw assemblies pivotably mounted with respect to one another,wherein the first jaw assembly includes a first jaw member and thesecond jaw assembly includes a second jaw member; the first jaw memberincluding: a first arm member defining at least one aperture at leastpartially therethrough; and a first support base extending distally fromthe first arm member; the second jaw member including: a second armmember defining at least one aperture at least partially therethrough;and a second support base extending distally from the second arm member;the first jaw assembly further including: a firstelectrically-conductive tissue-engaging structure; and a firstnon-electrically conductive member including a first portion configuredto engage the first electrically-conductive tissue-engaging structureand a second portion configured to engage the first support base of thefirst jaw member; the second jaw assembly further including: a secondelectrically-conductive tissue-engaging structure; and a secondnon-electrically conductive member including a first portion configuredto engage the second electrically-conductive tissue-engaging structureand a second portion configured to engage the second support base of thesecond jaw member; at least one pivot pin engaged with the apertures ofthe first and second jaw members such that the first and second jawassemblies are pivotably mounted with respect to one another; anelectrically insulative jaw insert attached to the first arm member; andan electrically insulative bushing having a first part and a secondpart, the first part larger than the second part and positioned betweenthe first and second arm members and configured to electrically isolatethe first jaw member from the second jaw member, the second partdisposed in the electrically insulative jaw insert.
 9. The end-effectorassembly of claim 8, wherein the first electrically-conductivetissue-engaging structure and the first non-electrically conductivemember cooperatively define a longitudinally-oriented knife channeltherethrough.
 10. The end-effector assembly of claim 8, wherein thefirst non-electrically conductive member includes a body defining afirst lateral side portion and a second lateral side portion, the firstand second lateral side portions joined at one end by an apex disposedat a distal end of the body and spaced apart at opposing ends to definean opening therebetween.
 11. The end-effector assembly of claim 10,wherein the opening is configured to receive at least a portion of thefirst support base of the first jaw member therein.
 12. The end-effectorassembly of claim 8, wherein the second jaw assembly is adapted toconnect the second electrically-conductive tissue-engaging structureassociated therewith to an electrosurgical generator.
 13. Anend-effector assembly, comprising: a first jaw assembly having a firstjaw member including: a first arm member defining a first aperture atleast partially therethrough; and a first support base extendingdistally from the first arm member; a second jaw assembly having asecond jaw member including: a second arm member defining a secondaperture at least partially therethrough; and a second support baseextending distally from the second arm member; a pivot pin engaged withthe first and second apertures such that the first and second jawassemblies are pivotably mounted with respect to one another; anelectrically insulative jaw insert attached to the first arm member; andan electrically insulative bushing having a first part and a secondpart, the first part larger than the second part and positioned betweenthe first and second arm members and configured to electrically isolatethe first jaw member from the second jaw member, the second partdisposed in the electrically insulative jaw insert.
 14. The end-effectorassembly of claim 13, wherein the first jaw assembly further includes afirst electrically-conductive tissue-engaging structure and the secondjaw assembly further includes a second electrically-conductivetissue-engaging structure in opposition to the firstelectrically-conductive tissue-engaging structure.
 15. The end-effectorassembly of claim 14, wherein the first electrically-conductivetissue-engaging structure is supported on the first support base and thesecond electrically-conductive tissue-engaging structure is supported onthe second support base.